Compact portable foldable solar panel support system and methods of use

ABSTRACT

Disclosed are methods and apparatus for providing portable solar array support systems. Embodiments of the invention include an apparatus that holds four 60-cell rooftop-grade solar panels and folds up into a relatively small portable device that easily fits in a garage or shed. When open, the panels are displayed at near the nominal angle to the sun for the region. Adjustable angle supports are available in alternative embodiments. Embodiments of the foldable solar array system are constructed from steel components, and feature proprietary integrated hinges to minimize the size and complexity of the system. The hinges are specially-cut sections of steel angle iron that force a solid stop point in the open or closed positions. These may be 90° hinges on the panel arms and swing arms, and may be 180° hinges on panel-to-panel hinges. The panel-to-panel hinges also allow for an offset based on the thickness of the solar panels and make the solar panels lay flat when open and stack face to face when closed. The weight from the use of steel is useful to help stabilize the array in windy conditions. Additional weight and/or ground anchors can also be easily applied and are recommended for use in windy environments.

BACKGROUND OF THE INVENTION

The present invention relates to providing solar power, and moreparticularly to portable solar array support systems that may be foldedinto a compact form for ease of transport, and which may then bedeployed in remote locations to support multiple large, heavy solarpanels that provide significant power that would otherwise not beavailable.

Solar panels have become more prevalent and less expensive in recenttimes, but there has been no simple and effective way to transport andquickly deploy a solar array of intermediate size. Larger solar systemshave a more permanent nature, since they are typically mounted on arooftop or on a large trailer; and smaller portable systems aretypically used for camping or emergency backup for power outages.Trailer-mounted and rooftop systems are bulky and expensive, and delivermuch more power, but they have a high cost and ordinarily requirepermitting. A typical small “portable” solar array is ordinarily capableof producing 100 to 300 watts of solar output. This is a very low amountof power which may be enough to operate one or two appliances, but isinsufficient if any significant number of items are to powered. Thepower available is even lower if the user considers that the solarsystem also has to recharge an inverter package for night or inclementweather use.

However, there is a gap between small portable emergency or campsitesolar panel systems and larger more permanent systems such as rooftop ortrailer-mounted systems. What is left is a significant demand forintermediate systems that are both portable and capable of powering alarge number of devices.

Embodiments of the present invention provide methods and apparatus whichaddress these needs.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide methods and apparatus forproviding portable solar array support systems that may be folded into acompact form for ease of transport, and which may then be deployed inremote locations to support multiple large solar panels that are capableof providing significantly more power than a small camping or emergencygenerator for energizing a significant number of items.

Embodiments of the foldable array (aka Fold Array) of the presentinvention include a highly transportable solar array support system thatfolds up into a very small footprint. This allows such systems topotentially be stored in a space as small as a closet or shed. More thanone foldable array can be nestled for even further efficiency of storagespace. With just a few moves, embodiments of the invention may be movedabout and deployed quickly and reliably by just one person of reasonablestrength.

In some aspects of the invention, a unique integrated hinge system isprovided as part of the design. Embodiments of this hinge system utilizesimple metal angle iron to force a positive stop at either 90° or 180°.The 90° hinges use the edge of the angle iron to make the positive stop.The 180° version is more unique. With careful shaping of the angle iron,a positive stop is also accomplished at 180° which is not possible forthe basic 90° version. Since the angle iron can be any length after thehinge shape at the end, the hinge can also offer on offset that is usedto displace the support of the solar panels assuring a very compactalignment when folded. This offset is carefully chosen to force thepanels to lay parallel to each other when in the open position. Thehinge protrudes so little when open that there is virtually no chancefor a shadow which is known to lessen the efficacy of solar panels. Theintegrated hinges also offer overlapping surfaces that can be easilypinned into place for greater strength and stability.

Embodiments of the invention also include two systems that help make theset up safe and accurate. The first of these is a swinging brace. Thissimple free-hanging appendage quickly takes the weight of the system asthe user tilts it into deployment position. Embodiments of the swingingbrace rest against a large handle that doubles as a primary steeringcomponent, much like a shopping cart. This is important since anopposite end of the array cart is often on wheels and could roll outfrom under the operator without the help of the brace. The secondfeature is a control arm that forms a parallelogram between the cart andthe angled legs. This forces the legs to present themselves at a 90°angle to the cart at all times. As each of the legs is directed intoplace, the angled leg is forced to follow. This assures that weight ofthe side panels is quickly assumed by the angled leg as it comes intocontact with the ground. This leg may also be set for a prescribed angleof the array. In some embodiments, there is a feature that provides foran opportunity to pin the side panels in place. Alternatively, the pinscan be left off if the user is on substantially uneven ground or thereis minimum concern for windy weather.

Portability is another feature of the foldable arrays of the presentinvention. Embodiments of the folded system can easily be pushed aboutlike a shopping cart. Large wheels may be provided to help roll overgrass and uneven ground. Embodiments having a wide, flat back helpstabilize the folded array in the case that it is stored or transportedon is back, such as, for example, on a pickup truck. In suchembodiments, the operator may roll the array up to the bed of the truckand then tilt it backward onto the bed of the truck. This presents alower profile sticking up out of the bed of the truck. The folded arraysof the present invention should always be secured with straps or othermeans like any cargo being transported in a moving vehicle.

Embodiments of the foldable array may hold the solar panels at a fixedangle to the sun. This angle is derived by the average angle of the sunin a given region. Typically that angle is specified by setting it at anangle equal to the latitude of the region in which the array is to beused. In a year, the sun will track approximately +/−15° from thisaverage angle. The swinging brace and angled legs can be substitutedwith different versions to make the open array present at theappropriate angle for the region in which it is used. In someembodiments, adjustable swinging braces and/or adjustable angled legsmay make it possible to alter the angle for more efficiency year-round.For exemplary purposes and without limitation, the embodiments detailedherein are set at 32°, which is the angle selected for use in NorthTexas.

In other embodiments, the foldable array of the present invention may bea fixed mount type. In these embodiments, the wheels and swinging braceare replaced with a framework that can be anchored to the ground. Theadvantage of this system over other permanent systems is that it can befolded up and secured in the event of hail. Hail is the single mostdangerous condition for solar panels, and is typically the only aspectthat is not guaranteed from solar panel manufacturers. Several of thesearrays placed in a checkerboard layout could provide a much largeroutput of energy. An added benefit is the ability to fold up the arraysand make the ground beneath more accessible for mowing and groundmaintenance.

Although most of the illustrated embodiments are designed for four solarpanels, it is to be appreciated that in other embodiments, one, two orthree panel systems may also be provided. For example, and withoutlimitation, a four-panel system may be reduced to a two-panel system byleaving off the outer two arms of the support frame. In that case, theangled legs could also be left off, but the cart and swinging bracewould remain the same. The inner panel support arms would be modified toeliminate the 180° hinges but add structures to allow for the use of thefront swivel casters. This would reduce the weight by approximately halfbut also the electrical output of the array would be reduced byapproximately half.

It is therefore an object of the present invention to provide portablesupport assemblies for intermediate sized solar panel arrays that areeasy to transport and capable of supporting multiple large solar panelsto provide more robust power to a number of items.

It is also an object of the present invention to provide methods ofmoving and supporting arrays of large solar panels in order to deploythem in remote locations or for domestic emergency use and providesignificantly more power than would otherwise be available.

It is also an object of the present invention to provide methods andapparatus for transporting and deploying multiple arrays of large solarpanels that are easy to assemble, easy transport, easy to adjust, easyto disassemble and which provide compact storage.

It is also an object of the present invention to provide portable solarpanel support and deployment systems for containing a nominal group offour solar panels that can be easily moved about and quickly be foldedclosed or unfolded open so as to make the solar panels present at afixed angle to the sun

It is also an object of the present invention to provide portable solarpanel support and deployment systems using a unique integrated hingesystem that creates a strong and positive stop at 0, 90, or 180 degreesand also allows an offset that compliments the thickness of the solarpanels attached thereto.

It is also an object of the present invention to provide portable solarpanel support and deployment systems having an integrated control armsystem that forces the movable angled support leg to deploy at 90degrees to the earth to quickly assume the weight of the open solarpanels.

It is also an object of the present invention to provide portable solarpanel support and deployment systems that use a swinging arm brace andpositive stop against the dual-purpose handle to quickly assume theweight of the initial action of tilting of the embodiment to present atthe nominal angle to the sun as prescribed by the current iteration ofthe embodiment.

It is also an object of the present invention to provide portable solarpanel support and deployment systems having a wheel system that, when inthe folded-up attitude, allows easy movement to the deployment locationin a similar fashion to a shopping cart.

It is also an object of the present invention to provide portable solarpanel support and deployment systems in which the substitution of justthree parts can allow a different fixed nominal angle to the sun for usein significantly different geographic regions of the country.

It is also an object of the present invention to provide portable solarpanel support and deployment systems that can easily be modified or usedas-is to support different sized solar panels as needed by the end user.

It is also an object of the present invention to provide portable solarpanel support and deployment systems that can be reduced in stature tosupport fewer panels as needed while maintaining the same basicproperties of the full embodiment.

It is also an object of the present invention to provide portable solarpanel support and deployment systems that can be used with an alternatebase unit to perform the same foldable solar panel functions in a fixedenvironment.

Additional objects of the invention will be apparent from the detaileddescriptions and the claims herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a list of component parts for an embodiment of the invention.

FIG. 2 is an exploded view of a folded array of an embodiment of theinvention.

FIG. 3 is a perspective view of a folded array of an embodiment of theinvention in a collapsed condition with solar panels.

FIG. 4 is a perspective view of a folded array of an embodiment of thein a collapsed condition invention without solar panels

FIG. 5 illustrates a first action of deployment of an embodiment of theinvention—tilting back.

FIG. 6 illustrates the completed first action of FIG. 5.

FIG. 7 shows location of the angled leg pins for removal in anembodiment of the invention.

FIG. 8 presents a top view of a second action of deployment of anembodiment of the invention—unfolding an inner wing.

FIG. 9 shows a perspective view of an embodiment of the invention withboth inner wings open—without solar panels.

FIG. 10 shows a perspective view of an embodiment of the invention withboth inner wings open—with solar panels installed.

FIG. 11 presents the third action of deployment an embodiment of theinvention—a perspective view of the folded array fully open, withoutsolar panels.

FIG. 12 shows a perspective view of an embodiment of the invention withthe folded array fully open—with solar panels installed.

FIG. 13 is a rear perspective view of an embodiment of the inventionshowing the location of stabilizing pins.

FIG. 14 is an exploded detail view of a proprietary 180° integratedhinge of an embodiment of the invention.

FIG. 15 is an exploded detail view of a 90° integrated hinge of anembodiment of the invention.

FIG. 16 is a perspective view showing the location of storage braces ofan embodiment of the invention.

FIG. 17 shows four steps of deployment of an embodiment of theinvention.

FIG. 18 is a perspective collapsed view of an alternative embodiment ofthe invention illustrating a folded 2-panel of array—with solar panels.

FIG. 19 is a perspective collapsed view of the 2-panel embodiment ofFIG. 18—without solar panels.

FIG. 20 is a perspective opened view of the 2-panel embodiment of FIG.18—without solar panels.

FIG. 21 is a perspective opened view of the 2-panel embodiment of FIG.18—with solar panels installed.

FIG. 22 is a perspective collapsed view of an alternative embodiment ofthe invention illustrating a stationary folded array.

FIG. 23 shows the folded stationary embodiment of FIG. 22—without solarpanels installed.

FIG. 24 shows the opened stationary embodiment of FIG. 22—without solarpanels installed.

FIG. 25 shows the opened stationary embodiment of FIG. 22—with solarpanels installed.

FIG. 26 is a rear view of an embodiment of the invention showing theorientation of a solar panel with respect to attaching the braces.

FIG. 27 shows the nominal orientation of an embodiment of the inventionwith respect to the path of the sun.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference characters designatelike or corresponding parts throughout the several views, and referringparticularly to the exemplary embodiments of FIGS. 3 and 12 (full mobileembodiment), 18 and 21 (two-panel mobile embodiment), 22 and 25(stationary embodiment), it is seen that in these illustratedembodiments, a support frame 10 (mobile embodiment) or 11 (stationaryembodiment) is provided having two additional support members or angledlegs 100, 110 (mobile embodiment) or 170 and 180 (stationaryembodiment), and two horizontal structural support groups 50, 70 (innerpair), and 60, 80 (outer pair). These support members may be made ofiron, steel, aluminum or other sturdy metal.

FIG. 1 discloses the following component parts: main cart 10; main cartaxle 20; exemplary ten inch (10″) wheels 30; swinging brace 40; righthand (RH) inner panel arms 50; RH outer panel arms 60; left hand (LH)inner panel arms 70; LH outer panel arms 80; angled leg control arm 90;RH angled leg 100; LH angled leg 110; exemplary six inch (6″) caster120; and storage braces 130. The view of these components in theexemplary embodiment of (FIG. 1) are based on the view of an operatorstanding behind the cart.

FIG. 2 is an exploded view of an example of a folded array with relativeposition of the components. In this embodiment, the cart 10 attaches tothe upper and lower inner panel arms 50 & 70 by way of 90° hinges (FIG.15). The angled legs 100 & 110 attach to the inner panel arms by way ofupper and lower 90° hinges and are directed by the control arms 90. Theouter panel arms 60 & 80 attach to the inner panel arms by way of 180°integrated hinges (FIG. 14). The wheels 30 mount to the cart using anaxle 20 which may be protected by an axle guard mounted to the cart 10.The swivel casters 120 attach to the bottom of the angled legs 100 &110.

FIG. 3 is an example of a folded array in the storage and transportposition (collapsed). This exemplary cart features an upper handle 101and a lower handle 102 that is used to steer the cart. The folded solarpanels 140 are bolted directly to the inner panel arms 50 which are inturn mounted to the upper 103 and lower 104 cart arms by use of 90°hinges (FIG. 15). The axle may be encased in a protective section ofsquare steel tubing 105 which is also the foot rest for the first actionof deployment described further in (FIG. 5). From the angle shown inFIG. 3, the inner panel arms 50 can be seen but the outer arms arefolded inside the center part of the folded cart system. The upper andlower panel arms now move as a group being coupled by the solar panel.This is true of each of the four pairs of upper and lower panel arms.The RH angled leg 100 is in the pinned position (FIG. 7) and furtherheld in place by the control arm 90. The cart is designed to be usedwith large wheels 30 (e.g., 10″ fixed rear wheels) and rotating frontcasters 120 (e.g., 6″ casters) for easy movement. The storage braces 130have been removed in this view to better show the front detail of thecart and are detailed further in (FIG. 16).

FIG. 4 is an example of a folded array in a collapsed position withoutsolar panels to better see the relationship of the frame components. Theupper cart handle 101, lower cart handle 102 are shown. Upper 103 andlower 104 cart arms hold the inner panel arms 50 by way of 90° hinges210 (see also FIG. 15). These arms are coupled to the outer panel armsusing 180° hinges 200 (see also FIG. 14). Both angled leg control arms90 are now visible. They direct the motion of the angled legs 100 & 110during deployment. The large rear wheels 30 and axle (not visible) maybe set at, for example and without limitation, 32.5″ wide overall tonavigate typical 36″ doorways, although other suitable distances may beused. The front wheels 120 may be closer together to minimize theoverall footprint for easier storage. Storage braces 130 are shownremoved.

FIG. 5 shows the first action of deployment. The upper handle 101 isused to pull the array backward and is chosen to allow greater leveragethan the lower handle while the operator places a foot on the axle brace(located between the wheels 30) and the swinging brace 40 falls backward(310) to come in contact with the ground without the operator having toposition it. Once in contact with the ground, the cart is pushed forward(300) to fully engage (310) the swinging brace 40 against the lower carthandle 102.

FIG. 6 shows the position of the cart 10 with the swinging brace 40fully engaged against the lower cart handle 102.

FIG. 7 shows the location of the wing pins (320) in an exemplaryembodiment. These may be, for example and without limitation, ¼-20×1″bolts which may use wing nuts that go through holes in the angled arm100 and the inner panel arm 50. The cart 10 with solar panels 140 is nowresting on the swinging brace 40 in order to be stable for thedeployment of the panel wings.

FIG. 8 is from the view atop the axis of an example of a cart anddemonstrates the action of the control arm 90 to keep the angled leg 100in alignment with the cart (331) as it is lowered (330) to the ground.The LH angled arm 110 is shown already in contact to the ground. Notethat the casters 120 may be rotated 90° to keep from blocking the angledlegs from lying flat on the ground. The outer panel arms 60 & 80 are nowon top. The action of control arms 90 in keeping angled legs 100 and 101in alignment with the cart is critical. This is because the solar panelsare heavy, and once the deployment begins, the force of gravity maycause them to move rapidly as they are unfolded. It is thereforeimportant for support legs 100 and 101 to remain aligned with the cart(and parallel with each other) so that they are immediately available toprovide ground support for the solar panels when they are fully opened,as shown with reference to leg 110 of FIG. 8. It is to be appreciatedthat while each solar panel is being moved from a generally verticalposition (as shown in FIG. 6) to a generally horizontal position (asshown in FIG. 10), legs 100 and 110 remain parallel to each other,through the action of control arms 90.

FIG. 9 shows an example of two inner wings in the open position with thesolar panels removed for clarity. The outer panel arms 60 & 80 are nowon top. The angled legs 100 & 110 are flat on the ground. The outerpanel arms are still held in the closed position by the 180° hinges 200.

FIG. 10 is the same as (FIG. 9) except with the solar panels 140 inplace.

FIG. 11 is step three of the deployment and is a skeletal view of thesystem fully deployed. The inner panel arms 50 & 70 are coupled to theouter panel arms 60 & 80 by way of the 180° integrated hinges 200. Theoperator is encouraged to lift the outer panels open by grasping thepanel arms and not by the solar panels directly. FIG. 12 is the same as(FIG. 11) except with the solar panels 140 in place.

FIG. 13 is a rear view of an example of an open system showing thelocations (340) of the stabilizing pins behind the solar panels 140.These may be sets of ¼-20 machine hardware and may use washers and wingnuts. These are located on the 180° integrated hinges and at the outerends of the panel cart arms 103. The pins are recommended to lock thesystem in place so it has greater resistance to wind but are notrequired for the system to function.

FIG. 14 is a detail of an example of a 180° proprietary panel hingeswhich may be integrated into the unit. The novel feature is the abilityto create a positive stop (351) in the closed (350) position. Anotherpositive stop (353) occurs in the open (352) position. The extended endsalso allow for offset attachment of the panel arms so that the solarpanels have sufficient clearance to close face-to-face. Refer to theinsert (356) of (FIG. 14) as well as (FIG. 3) to better appreciate thisrelationship. The insert shows an x-ray view of the hinge with the panelbrace attached where the dotted lines represent the immediate crosssection of the solar panels 140. The hardware stack for the integratedhinge may include one ⅜-16×1″ stainless steel bolt 201, two ⅜″ stainlesssteel washers 202, one stainless steel fender washer 204 to providesmoother action and separate the halves of the hinge 203 & 205 and one⅜-16 stainless steel lock nut 206 with nylon insert.

Each 180° hinge 200 includes a pair of flanges, each flange having anL-shaped cross section. Each flange includes a flat bottom (horizontal)edge (355) having a rounded extension thereon with an opening thereinfor receiving a bolt, such as 201 which acts as a pivot. Each flangealso includes a side (vertical) edge (354). The hinge may be closed(350) by rotating the flanges inward around pivot 201 until the verticaledges make contact with each other (351), stopping the opening movement.The hinge may be opened (352) by rotating the flanges in the oppositedirection outward around pivot 201 until the horizontal edges makecontact with each other (353), stopping the opening movement.

Refer to insert drawing (356) of FIG. 14 for a better understanding ofthe references to ‘open’ (352) and ‘closed’ (350) with respect to thepanel arms and solar panels themselves 140 (dotted lines). Thesespecialty hinges are key to the efficient deployment of the solarpanels.

FIG. 15 is a detail of an example of a 90° hinge that may be integratedinto the unit. It has the same hardware stack as the 180° hinge detailedin (FIG. 14). This example is one of the RH inner panel arms 70 where itattaches to the cart 10 arm 104. This type of hinge has a positive stopat 90° (360).

Each 90° hinge 210 includes a movable flange 70 having an L-shaped crosssection with a flat bottom (horizontal) edge (361) having a roundedextension thereon with an opening therein for receiving a bolt, such as201, which acts as a pivot. Flange 70 is rotatably mounted to crossmember 104 at 210. The flange 70 also includes a side (vertical) edge(362). The hinge 210 may be opened by rotating the flange 70 outwardaround pivot 210 until the vertical edge (362) makes contact with crossmember 104, stopping the movement. The hinge 210 may be closed byrotating (360) flange 70 in the opposite direction around pivot 210until the horizontal edge makes contact with the horizontal edge (363)of cross member 104, stopping the opening movement.

In like manner as the description of the 180° hinge in (FIG. 14), thereferences to ‘open’ and ‘closed’ are consistent with the ultimateattitude of the solar panels mounted thereto. Flange 70 in FIG. 15 isshown in a ‘closed’ position; rotating it outward in the direction shownby the arrow (360) will move it to an ‘open’ position.

FIG. 16 details how and where an example of the storage braces 130attach. They sit on the corners of the inner panel arms 50 and may beattached using two sets of ¼-20 stainless steel hardware with wing nutson each (320). Once removed, the hardware may be used as the stabilizingpins for the panel arms FIG. 13.

FIG. 17 illustrates the steps to deploy an embodiment of the invention.In order to stay on a single page, the starting image is in the lowerleft corner and the steps are displayed in clockwise order. Image one(370) shows the folded array in the storage/transport position with thestorage braces 130 removed. Image two is the first stage of deployment(371) and shows the still-folded array tilted back onto the swingingbrace. This is where one of the diagonal leg pins would be removed andthe inner panel group lowered to the ground (372) which is step two.After the second diagonal leg pin is removed, both inner panel groupswould be lying flat on the ground (372) and the front casters rotatedsideways to make the system lay flat. After pinning the inner panel armsas needed, the outer ‘wing’ panels are opened and pinned completing thethird and final step of deployment (373).

FIG. 18 illustrates a smaller 2-panel embodiment of an example of afoldable array. This system uses the same cart design 11 except that theinner arm pivot points are closer together 106. Since the weight of thepanels is half as much, the need for the angled legs is replaced with asimple pair of legs 150 that are welded to the upper and lower innerpanel arms 71, but may still use the same casters 120 (e.g., 6″) asbefore. The 180° integrated hinges are also eliminated as there are noouter panels to deploy.

FIG. 19 is the same 2-panel embodiment of (FIG. 18) with the solarpanels removed to see the complete frame. This has only four movingparts compared to the full 4-panel system. The upper and lower panelarms are combined with straight legs 150 & 160 to provide a place tomount the swivel casters 120. In this drawing it is now clearer how thepanel cart 11 is modified 106 to keep the two solar panels closertogether.

FIG. 20 shows an example of a fully deployed 2-panel embodiment and theframe components. The inner panel arms 71 may both be welded to thecaster posts to form combined panel support and caster legs 150 & 160.The swinging brace 40 rests against the lower cart handle 102 in thesame fashion as the 4-panel system.

FIG. 21 is the same as (FIG. 20) except that the solar panels 140 areshown in position.

FIG. 22 is an example of another embodiment where the cart is modifiedto have a fixed base 11 which now incorporates fixed braces 41 thatreplace the swinging arm from the portable versions. The entire foldingsystem is the same as the original portable foldable array except theangled legs 170 have been shortened and the casters removed (374).

FIG. 23 is the same as (FIG. 22) except that the solar panels areremoved to show the entire mechanism. The inner panel arms 50 & 70,outer panel arms 60 & 80 and control arms 90 are the same as theoriginal foldable array. The angled legs 170 (and 180, not shown)operate the same way as the angled legs described in (FIG. 8) and havingthe same geometry as the original design except there is no longer anyneed for the casters and the overall length has been reduced forcompactness.

FIG. 24 is an example of a stationary folded array version in the openposition without solar panels. The base 11 is like the portable cartexcept for a fixed framework and no wheels. The swinging brace has nowbeen integrated and has become a fixed part of the frame that is securedto the ground. The inner panel arms 50 & 70 are still attached to thecart turned stationary base 11 with 90° hinges 210 and the outer panelarms 60 & 70 are still attached by the 180° hinges 200. It is easy tocompare this framework with (FIG. 11) as all of the parts are generallythe same except for the stationary base and truncated diagonal legs.

FIG. 25 shows an example of a stationary embodiment of a folded array inthe fully deployed position with the solar panels 140 installed andcompares to the portable folded array shown in FIG. 12.

FIG. 26 shows the basic orientation of a solar panel 140 with respect tothe attachment of the control arms. This example is the RH solar paneland RH inner control arms 50.

FIG. 27 shows the recommended orientation of the cart system as thefirst step of deployment with respect to the path of the sun. The centerof the path (376) should be roughly south in nature

By way of example and without limitation, one embodiment of the presentinvention is described below. Currently, the most common sizes ofrigid-frame solar panels intended for rooftop mounting are 60-cell and72-cell. The smaller, 60-cell, typically have a dimension of 39″ acrossand 69″ tall. In this example, the smaller of the two common sizes isutilized. It is to be appreciated that larger versions could easily bescaled up for 72-cell panels, or ultimately any size panel in thisrange. By selecting the 60-cell panels, the objective in this example isto deliver a quickly-deployed system with the nominal full-sun outputcapacity of 1000 watts or more. Installing four 260-watt panels achievesthis goal. Thus, the design goals for this example system are:

-   -   1) Hold four 60-cell solar panels of 39″ of width;    -   2) Can be moved about and deployed by one person of reasonable        strength;    -   3) System locks into place open or folded to maximize wind        resistance;    -   4) Weather-resistant;    -   5) Folded system can pass through a standard 36″ doorway;    -   6) Folded system or systems can fit into and be transported in a        pickup truck bed;    -   7) Folded system has minimal footprint for storage;    -   8) Disassembled components lay near flat for easy shipment or to        fit into a SUV;    -   9) Deployed system automatically assumes a fixed angle to the        sun;    -   10) Simple substitution of minimal parts creates alternate        angles of use;    -   11) Stable during setup, and stable enough to withstand 25 mph        wind    -   12) Optional adjustable angle.

With these features, this example foldable solar array support systemwould be the basis for a much more effective backup power system foremergencies than others currently on the market. The foldable array isstill small enough to be transported in the back of a pickup truck, thusexpanding its potential use. Additionally, the foldable array system isalso small enough for more than one unit to be transported in a pickuptruck or larger vehicle at the same time.

The user of a system of this example may configure the electrical outputof the solar panels held in this foldable array in a number of ways.Some of these are:

-   -   1) Grid-tie use to offset home energy consumption and reduce        electricity bills;    -   2) Inline backup UPS-style use to augment intermittent or        unreliable power;    -   3) Stand-alone electrical power source with an added battery and        inverter package;    -   4) Any other use that can make use of the output of four 60-cell        solar panels.

Easy access to the wiring on the back of the solar panels allows for avariety of electrical configurations, troubleshooting or electricalreconfiguration.

By way of example and without limitation, an embodiment of the presentinvention may be setup, used and taken down as follows:

Before assembling any embodiment of a fold array, the user should checkto make sure the necessary parts are available. In this particularembodiment, the following nonexclusive list of parts (see FIG. 1) may beused:

REFER- QUAN- ENCE TITY ITEM 10 1 cart 20 1 ⅝″ axle rod 30 2 10″ rubbertires (ns) 2 1¼″ cotter pins (not shown individually) 40 1 swingingbrace 50 2 RH inner panel arms 60 2 RH outer panel arms 70 2 LH innerpanel arms 80 2 LH outer panel arms 90 2 control arms 100 1 RH diagonalleg 110 1 LH diagonal leg 120 2 6″ swivel casters 130 2 storage/handlingbraces (ns) 4 ⅝″ washers (not shown individually) 201 22 ⅜″ × 1″stainless steel hex bolts 204 14 ⅜″ stainless steel fender washers 20236 ⅜″ stainless steel regular washers 206 22 ⅜″ stainless steel locknuts (ns) 20 5/16″ × ¾″ stainless steel hex bolts (not shownindividually) (ns) 44 5/16″ stainless steel washers (not shownindividually) (ns) 20 5/16″ stainless steel lock nuts (not shownindividually) 320 8 ¼-20 stainless steel hex bolts (shown as a group)320 16 ¼″ stainless steel washers (shown as a group) 320 8 ¼-20stainless steel wing nuts (shown as a group) (ns) 1 drill template (notshown) (ns) 1 instruction book (from which this section excerpted from)

This exemplary embodiment of the invention is designed to use REC PeakEnergy Z-Link 260 watt 60-cell panels, although other panels with otherwattages having a nominal width of approximately 39 inches may also beused. A vertical spacing of 39″ (centers) and 37″ horizontal (centers)is desirable for the screw holes in the solar panel frames. The holesshould be 5/16″ in diameter. In some cases, additional holes are neededon the back of the solar panel frames. If additional holes are needed,the following procedure is recommended:

-   -   1) Place the drill template (not shown) along one of the long        edges of the aluminum panel frame and centered along that side.    -   2) Place a small block of wood and/or firm metal under the edge        of the frame where the holes will be drilled to protect the back        of the solar panel.    -   3) Using a ⅛″ drill bit, be careful to drill a pilot hole only        through the first layer of the aluminum frame.    -   4) Using a shallow stepped drill bit and with equal care,        enlarge the holes to 5/16 inches.

The cart of this exemplary embodiment may be assembled as follows:First, the axle and wheels are attached to the cart. This may requirethe cart 10, axle 20, 10″ fixed wheels 30, ⅝″ washers (not shown) andcotter pins (not shown). The axle should be slid through the axleprotector at the bottom of the cart frame. A washer should be placed oneither side of the wheel and all three should be slipped onto one end ofthe axle. A cotter pin should be used at each end, with tabs bent outenough to stay in place. Some wheels have different tolerances and ifeverything does not fit at once, the inner washers may be removed formore space. Repeat this procedure for the wheel 30 on the other side ofthe cart.

The angular legs 100, 110 are then prepared by attaching the swivelwheels to the angular legs with ⅜″ bolts 201, two ⅜″ washers 202 and a⅜″ lock nut 206. This is done for both legs. These should be welltightened. For panel arms, the open side should face the top of thepanel.

The solar panels are then attached to the arms (FIG. 26). First, theeight panel arms two each of 50, 60, 70 and 80 and four solar panels 140should be located. Each panel will use two identical arms. Note theorientation of the solar panel with respect to the wiring box 375 at thetop of the rear of the solar panel. Each mounting point should use a5/16″×¾″ set of hardware (bolt, nut & two washers; not shown). Depthshould be checked before starting, after which the bolt is droppedthrough panel arm and hole in back of solar panel 140 frame. Thereshould be a gap between the bolt end and the solar panel.

The first framed panel is then ready to be attached to the cart 10. TheRH inner panel should be checked to confirm that its vertical spacingfor the arms (50 or 70) matches the ones on the cart 10. Using at least2 people, the cart should be raised enough to position the panel ontothe frame. The curved end of the framed panel arms should be set on topof the metal frame of the cart. A ⅜″ bolt 201 should be dropped througheach hole to keep the frame from sliding around but without the nut (fornow). Before adding the nut, a ⅜″ fender washer 204 slides in betweenthe panel frame arm and the cart frame. A regular ⅜″ washer is thenadded to the top and bottom before threading the lock nut 206. The nutshould be tightened fully then backed it off ⅛ turn. The same should bedone for the other nut. This is the integrated hinge that will be usedfrequently in this system.

At this point, one of the triangular legs should be completed to helpkeep the cart stable for the rest of the assembly.

To attach the first diagonal leg, the RH leg 100 should be located andattached to the inner panel frame 50 & 50. The same stack of ⅜″ hardwareshould be used as was used for the frame to cart attachment. Once thetwo sets of hardware are attached and backed off ⅛ turn, one set of ¼-20hardware should be installed as shown (FIG. 7) to keep the leg upagainst the inner panel frame. This is the wing lock. This should not beleft unattended as it can still roll to an unstable condition. Astabilizer control arm 90 and two sets of 5/16″ hardware (bolt 201,three washers 202 and one nut 206 should be located. This is the samestack as the ⅜″ except the center washer is a regular washer. Both endsof the stabilizer arm should be attached to the top of the triangularleg and cart.

The other inner panel and triangular leg should then be attached (FIG.3). The following steps are the only time a user should open any of thepanels with the cart upright and only one at a time. CAUTION: NEVER OPENBOTH SIDES WHILE THE CART IS STANDING UPRIGHT. This will cause an unsafecondition which could result in a catastrophic fall.

Next is installation of the outer panels. After locating one of theouter panel frames, the ¼-20 hardware is removed from the wing lock onone side. The panel should be swung out far enough to reach the insideof the group. The corresponding outer panel frame, with mounting armsattached, is then bolted on place in the same fashion as the inner panelexcept that the hinge is away from the cart. Then this is folded backup, re-secured with the ¼-20 hardware and repeated for the other side.The storage stabilizers are attached next. The stabilizer 130 attachesto the hinge sets away from the cart. A ¼-20 wing nut group is used oneither end, one on each hinge group.

If the swinging brace 40 is not pre-assembled, it is attached asfollows. The brace sits inside the cart chassis with ⅜″ fender washersin between. Set the flat edge away from the cart. Thread ⅜″ hardware asbefore and remember to back off ⅛ turn. This brace rotates down forstorage but will later be raised and rest against the lower cart handlewhen deployed.

The exemplary array may now be used. It is to be noted that the rigshould always be handled by the gray steel parts, not by the solarpanels or their frames. To deploy the folded array (Fold Array) thefollowing steps should be used:

1) Move the folded cart to a place with good visibility to the arc ofthe sun (FIG. 27). Estimate the center of that arc 376 and point thecart toward it. This will be roughly south. Use more than one person ifthe terrain is rough or uneven.

2) Take off the storage braces (FIG. 16) by removing the wing nutsholding them onto the rig. These are the two pieces of metal 130 holdingthe hinges on the narrow end together. Save the ¼-20 hardware forpinning the panels later and store the loose braces 130 for later.

3) Tilt the rig back onto the swinging brace (FIG. 5). Place a foot ontothe axle protector 105 and pull back on the 101 upper handle. As the rigis lowered, allow the swinging brace 40 to touch the ground. Then pushthe rig forward to press the brace against the lower handle 102. This isthe heaviest part, and may require more than one person to accomplish.

4) Remove one of the diagonal arm pins (FIG. 7). This is another ¼-20hardware set with a wing nut. Be aware that the angled leg will followand position itself as that side is lowered to the ground (FIG. 8).Rotate the swivel wheel 120 to allow the rig to lay flat. If onnear-level ground, use the ¼-20 hardware to pin down the inner wingpanel that was just lowered. Repeat for the other side. If the rig hasto be lifted to get the pins in place, this should not be done bylifting on any solar panel directly. In the event of very uneven ground,these pins might not be practical to use.

5) Open the outer wings by lifting on the gray steel arms. When fullyopen (FIG. 12), these can also be pinned (FIG. 13). Use the same hole asthe storage brace which should now line up with the hole in the oppositeside of the hinge.

6) Follow the instructions on placement and hook-up of the inverterpackage selected by the user.

7) Disassembly is the reverse of assembly.

By way of example, and without limitation, the following simplifiedprocedure (in plain language) may be followed by persons alreadyexperienced in the nuances of this exemplary embodiment to deploy anarray of the present invention (refer to FIG. 17 for the following):

-   -   1) Position cart facing estimated center of day's sunshine path        (also see FIG. 27).    -   2) Remove two storage braces 130 and set braces and ¼″ hardware        aside 370 and (also see FIG. 16).    -   3) Using upper cart handle, tilt the rig backwards until        swinging brace touches the ground (also see FIG. 5).    -   4) Push the rig forward until swinging brace rests against lower        cart handle 371 (also see FIG. 6).    -   5) Remove wing nut (also see FIG. 7; 320) on one side of angled        leg and unfold leg to the ground (also see FIG. 7 and FIG. 8).    -   6) Repeat same for other side 372.    -   7) Re-attach four wing nuts sets as needed to stabilize wing        panel frames.    -   8) Un-fold the outer solar panels 373 and (also see FIG. 11 and        FIG. 12).    -   9) These can also be pinned at the hinges for additional        stability (also see FIG. 13).    -   10) Attach DC power cable to inverter package.    -   11) Re-folding unit for storage/transport is opposite of        deployment steps.

Set forth below is a sample set of specifications for one embodiment ofthe present invention:

Dimensions folded: 32.500″ wide 50.125″ deep 75.750″ tall Dimensionsopen: 173.250″ wide 63.125″ deep 43.375″ tall Nominal angle of tilt: 32degrees (for this example) Weight of frame only: 131 pounds Weight w/solar panels: 304 pounds (with four 43# solar panels) Frame shippingweight: 160 pounds (crated)

In many embodiments, the frame may be welded from ordinary steel andwill rust if given the chance. It is recommended that any places thathave the paint scraped off be restored periodically with an anti-rustproduct or flat primer gray. The bottoms of the swinging brace (40) anddiagonal legs that come in contact with the ground (110, 120, 170 and180) are more likely to need this from time to time. One way to limitscraping damage is to wrap the part of the legs that touches the groundwith pipe insulation or a foam pool noodle.

In many embodiments, lubrication is important. A coat of grease or oilwill slow down the natural deterioration of the integrated hinges. A 40weight lubricating oil or spray lithium grease should be used. The wheelbearings including the swivel for the front wheels should also beperiodically lubricated.

The efficiency of most solar panels is directly affected by anythingthat reduces the sunlight. It is therefore recommended that the (blue)surface of the solar panels be wiped down with a glass cleaner at thebeginning of every deployment and whenever dirt accumulates on thesurface of the panels. Periodic cleaning of the rest of the system canbe accomplished with a garden hose and medium-hard brush like might beused for washing a car. Everything should be allowed to dry beforemoving to storage.

It is to be appreciated that solar panels are made of glass, so the rigshould be stored or deployed away from objects that might fall onto therig. If storing more than one rig, they can be alternated facingopposite directions to make best use of storage space. It is possible,but not recommended that the rig can be placed on its back. Rememberthat it is very heavy and the swinging brace will be in the way.

For transport, the storage braces should be installed when moving thearray from one place to another. If the rig can be kept upright, thatwill be the best way to move it. If not, it can be tilted onto its backto load onto the bed of a pickup truck. Be sure to strap it down eitherway. An additional strap around the middle of the rig is alsorecommended. The ratchet mechanism or any metal parts of the strapshould be kept well away from the glass surface (front or back) of thesolar panels.

It is to be understood that variations and modifications of the presentinvention may be made without departing from the scope thereof. Inparticular, and without limitation, each of the various features and/oraspects of each embodiment disclosed herein may be used with otherfeatures and/or aspects of other embodiment disclosed herein indifferent combinations. Other combinations of features of the variousembodiments disclosed herein are also included within the scope of theinvention. It is also to be understood that the present invention is notto be limited by the specific embodiments disclosed herein, but only inaccordance with the appended claims when read in light of the foregoingspecification.

What is claimed is:
 1. A portable solar panel support system comprisinga. a central support frame comprising a pair of elongated parallel sidemembers, a first cross member attached to and extending between the sidemembers at upper ends thereof, and a second cross member attached to andextending between the side members at lower ends thereof, said framehaving a front and a back; b. a movable brace pivotally attached to saidside members at the back of said frame; and c. a first pair of solarpanel supports pivotally attached at one end to said first and secondcross members, wherein each of said first pair of solar panel supportscomprises a flange having a vertical member and a horizontal memberforming an L-shaped cross section, and each of said first and secondcross members comprises a flange having a vertical member and ahorizontal member forming an L-shaped cross section, such that pivotaloutward rotation of each of said first pair of solar panel supports isstopped when the horizontal member of the solar panel support makescontact with a vertical member of one of said first and second crossmembers, and pivotal inward rotation of each of said first pair of solarpanel supports is stopped when the vertical member of the solar panelsupport makes contact with a vertical member of one of said first andsecond cross members.
 2. The support system of claim 1 furthercomprising: a. a pair of angled support legs, each such leg beingpivotally attached at opposite ends of each of said first pair of solarpanel supports, and b. a pair of control arms, each control arm havingone end pivotally attached to said frame, and an opposite end pivotallyattached to one of said angled support legs, wherein said control armscause said legs to maintain a parallel orientation to each other duringmovement of the first pair of solar panel supports.
 3. The supportsystem of claim 2 further comprising a second pair of solar panelsupports pivotally attached at opposite ends of each of said first pairof solar panel supports wherein each of said first second of solar panelsupports comprises a flange having a vertical member and a horizontalmember forming an L-shaped cross section.
 4. The support system of claim3 wherein pivotal outward rotation of each of said second pair of solarpanel supports is stopped when a vertical member of a second solar panelsupport makes contact with a vertical member of a first solar panelsupport, and wherein pivotal inward rotation of each of said second pairof solar panel supports is stopped when a horizontal member of thesecond solar panel support makes contact with a vertical member of afirst solar panel support.
 5. The support system of claim 1 furthercomprising a pair of wheels attached to said frame at opposite ends ofsaid second cross member.
 6. The support system of claim 5 furthercomprising a pair of casters attached to lower ends of each of saidangled support legs.
 7. The support system of claim 1 further comprisinga plurality of solar panels deployed on said frame.
 8. The supportsystem of claim 1 further comprising a stop for holding said brace in afixed position.
 9. A method of deploying solar panels for use in remotelocations comprising the steps of: a. Attaching a plurality of solarpanels to a frame, the frame comprising (i) a central support framecomprising a pair of elongated parallel side members, a first crossmember attached to and extending between the side members at upper endsthereof, and a second cross member attached to and extending between theside members at lower ends thereof, said frame having a front and aback; (ii) a movable brace pivotally attached to said side members atthe back of said frame; (iii) a first pair of solar panel supportspivotally attached at one end to said first and second cross memberssupporting a pair of solar panels; (iv) a pair of angled support legs,each such leg being pivotally attached at opposite ends of each of saidfirst pair of solar panel supports; (v) a pair of wheels attached tosaid frame at opposite ends of said second cross member; and (vi) a pairof control arms, each control arm having one end pivotally attached tosaid frame, and an opposite end pivotally attached to one of said angledsupport legs b. Collapsing the frame and panels in to a compactcondition; c. Transporting the collapsed frame and panels to a desiredlocation; d. Positioning the frame facing an estimated center of theday's sunshine path; and e. Erecting the frame by (i) tilting the frameback against the movable brace; (ii) unfolding the first of said pair ofsolar panel supports until the angled support leg of said support makescontact with the ground; (iii) unfolding the second of said pair ofsolar panel supports until the angled support leg of said support makescontact with the ground.
 10. The method of claim 9 wherein said controlarms cause said legs to maintain a parallel orientation to each otherduring movement of the first pair of solar panel supports.
 11. Themethod of claim 10 wherein each of said first pair of solar panelsupports comprises a flange having a vertical member and a horizontalmember forming an L-shaped cross section, and each of said first andsecond cross members comprises a flange having a vertical member and ahorizontal member forming an L-shaped cross section, such that pivotaloutward rotation of each of said first pair of solar panel supports isstopped when the horizontal member of the solar panel support makescontact with a vertical member of one of said first and second crossmembers, and pivotal inward rotation of each of said first pair of solarpanel supports is stopped when the vertical member of the solar panelsupport makes contact with a vertical member of one of said first andsecond cross members.
 12. The method of claim 11 wherein said framefurther comprises a second pair of solar panel supports pivotallyattached at opposite ends of each of said first pair of solar panelsupports supporting a second pair of solar panels, and comprising theadditional steps of: a. unfolding the first of said second pair of solarpanel supports until the solar panel thereon is in planar alignment withan adjacent solar panel; and b. unfolding the second of said second pairof solar panel supports until the solar panel thereon is in planaralignment with an adjacent solar panel.
 13. The method of claim 12wherein each of said first second of solar panel supports comprises aflange having a vertical member and a horizontal member forming anL-shaped cross section wherein pivotal outward rotation of each of saidsecond pair of solar panel supports is stopped when a vertical member ofa second solar panel support makes contact with a vertical member of afirst solar panel support, and wherein pivotal inward rotation of eachof said second pair of solar panel supports is stopped when a horizontalmember of the second solar panel support makes contact with a verticalmember of a first solar panel support.
 14. A portable solar panelsupport system comprising a. a central support frame comprising a pairof elongated parallel side members, a first cross member attached to andextending between the side members at upper ends thereof, and a secondcross member attached to and extending between the side members at lowerends thereof, said frame having a front and a back; b. a movable bracepivotally attached to said side members at the back of said frame; c. afirst pair of solar panel supports pivotally attached at one end to saidfirst and second cross members, wherein each of said first pair of solarpanel supports comprises a flange having a vertical member and ahorizontal member forming an L-shaped cross section, and each of saidfirst and second cross members comprises a flange having a verticalmember and a horizontal member forming an L-shaped cross section, suchthat pivotal outward rotation of each of said first pair of solar panelsupports is stopped when the horizontal member of the solar panelsupport makes contact with a vertical member of one of said first andsecond cross members, and pivotal inward rotation of each of said firstpair of solar panel supports is stopped when the vertical member of thesolar panel support makes contact with a vertical member of one of saidfirst and second cross members; d. a pair of angled support legs, eachsuch leg being pivotally attached at opposite ends of each of said firstpair of solar panel supports; e. a pair of control arms, each controlarm having one end pivotally attached to said frame, and an opposite endpivotally attached to one of said angled support legs, wherein saidcontrol arms cause said legs to maintain a parallel orientation to eachother during movement of the first pair of solar panel supports; and f.a second pair of solar panel supports pivotally attached at oppositeends of each of said first pair of solar panel supports wherein each ofsaid first second of solar panel supports comprises a flange having avertical member and a horizontal member forming an L-shaped crosssection wherein pivotal outward rotation of each of said second pair ofsolar panel supports is stopped when a vertical member of a second solarpanel support makes contact with a vertical member of a first solarpanel support, and wherein pivotal inward rotation of each of saidsecond pair of solar panel supports is stopped when a horizontal memberof the second solar panel support makes contact with a vertical memberof a first solar panel support.
 15. The support system of claim 14further comprising a pair of wheels attached to said frame at oppositeends of said second cross member.
 16. The support system of claim 14further comprising a pair of casters attached to lower ends of each ofsaid angled support legs.
 17. The support system of claim 14 furthercomprising a plurality of solar panels deployed on said frame.
 18. Thesupport system of claim 14 further comprising a stop for holding saidbrace in a fixed position.